Methods of joining metal golf club components with projection resistance welding

Abstract

A method of joining dissimilar metal, golf club components, and particularly golf club bodies, hosels, and faces, using a projection resistance welding process is disclosed herein. The method may include the step of applying an interlayer material before the projection resistance weld process occurs.

We claim: 
     
       1. A method comprising the steps of:
 preparing a first golf club component comprising a first metal material; 
 preparing a second golf club component comprising a second metal material; 
 applying an interlayer material to at least one of the first golf club component and the second golf club component, wherein the first metal material is different from the second metal material; and 
 affixing the first golf club component to the second golf club component along a plane via a projection resistance weld joining process. 
 
     
     
       2. The method of  claim 1 , wherein the interlayer material is selected from the group consisting of tungsten, molybdenum, niobium, tantalum, vanadium, and zirconium. 
     
     
       3. The method of  claim 1 , wherein the first metal material is selected from the group consisting of 17-4 stainless steel, 304 stainless steel, 304L stainless steel, 321 stainless steel, 303 stainless steel, 316 stainless steel, 316L stainless steel, 420 stainless steel, 425 stainless steel, 425M stainless steel, 450 stainless steel, 455 stainless steel, 475 stainless steel, and HSR300 stainless steel, and wherein the second metal material is not a stainless steel material. 
     
     
       4. The method of  claim 1 , wherein the first metal material is selected from the group consisting of 6061 aluminum, 6063 aluminum, and 7075 aluminum, and wherein the second metal material is not an aluminum material. 
     
     
       5. The method of  claim 1 , wherein the first metal material is selected from the group consisting of 6-4 titanium, 811 titanium, FS2S titanium, FS2S+ titanium, SP700 titanium, Ti 17, Ti 21, and 15-3-3-3 titanium, and wherein the second metal material is not a titanium material. 
     
     
       6. The method of  claim 1 , wherein the first metal material is selected from the group consisting of C300 maraging steel, 1020 steel, 1025 steel, 1045 steel, 4130 steel, 4140 steel, and 4340 steel, and wherein the second metal material is not a steel material. 
     
     
       7. The method of  claim 1 , wherein the first metal material is a tungsten alloy having a density of 10 g/cc to 18 g/cc, and wherein the second metal material is not a tungsten alloy. 
     
     
       8. The method of  claim 1 , wherein the first golf club component is selected from the group consisting of a weight component, a stiffening component, and a strengthening component, and wherein the second golf club component is a body component. 
     
     
       9. The method of  claim 8 , wherein the body component is selected from the group consisting of a hollow body, a solid body, and a body having at least one cavity. 
     
     
       10. The method of  claim 9 , wherein the body is composed of at least one piece. 
     
     
       11. The method of  claim 1 , wherein the first golf club component is a hosel component, and wherein the second golf club component is a body component. 
     
     
       12. The method of  claim 1 , A method comprising the steps of:
 preparing a first golf club component comprising a first metal material; 
 preparing a second golf club component comprising a second metal material; 
 affixing the first golf club component to the second golf club component along a plane via a projection resistance weld joining process; 
 wherein the first golf club component is selected from the group consisting of a weight component, a secondary variable face thickness component, a stiffening component, and a strengthening component, and wherein the second golf club component is a face component. 
 
     
     
       13. The method of  claim 12 , wherein the face component is selected from the group consisting of a face insert, a face plate, and a face cup. 
     
     
       14. A method comprising the steps of:
 providing a golf club body with a first planar joining surface; 
 providing a golf club face component with a second planar joining surface; 
 applying an interlayer material between the first planar joining surface and the second planar joining surface, and wherein the interlayer material is composed of a third metal alloy that is different from the first metal alloy and the second metal alloy; and 
 affixing the first planar joining surface to the second planar joining surface via a projection resistance welding process, 
 wherein the golf club body is composed of a first metal alloy, and 
 wherein the golf club face component is composed of a second metal alloy that is different from the first metal alloy. 
 
     
     
       15. The method of  claim 14 , wherein the interlayer material is selected from the group consisting of tungsten, molybdenum, niobium, tantalum, vanadium, and zirconium. 
     
     
       16. The method of  claim 14 , wherein the first metal alloy is selected from the group consisting of 17-4 stainless steel, 304 stainless steel, 304L stainless steel, 321 stainless steel, 303 stainless steel, 316 stainless steel, 316L stainless steel, 420 stainless steel, 425 stainless steel, 425M stainless steel, 450 stainless steel, 455 stainless steel, 475 stainless steel, and HSR300 stainless steel, and wherein the second metal alloy is not a stainless steel material. 
     
     
       17. The method of  claim 14 , wherein the first metal alloy is selected from the group consisting of 6061 aluminum, 6063 aluminum, and 7075 aluminum, and wherein the second metal alloy is not an aluminum material.